Liquid refinement

ABSTRACT

Embodiments disclosed herein relate to an apparatus for refining a liquid stream which includes a liquid carrier with a heavier waste and a lighter waste. The apparatus includes a first flow chamber, a second flow chamber, and plates. The first flow chamber is a cone structure and directs the liquid stream downwards in a first direction at a first velocity. The first velocity is greater than a settling velocity of a heavier waste in the liquid carrier. The second flow chamber directs the liquid carrier upwards in a second direction at a second velocity less than the settling velocity. The plates are in the second flow chamber and at a transition between the first and second flow chambers. The plates have an inclined geometry to cause laminar flow in the liquid stream to separate the heavier waste to a lower collection chamber and lighter waste to an upper collection reservoir.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 15/055,478, filed Feb. 26, 2016, which claims the benefit ofU.S. Provisional Patent Application Nos. 62/121,660 and 62/121,673,filed Feb. 27, 2015, and U.S. Provisional Patent Application No.62/204,327, filed on Aug. 12, 2015, which are all incorporated herein byreference.

FIELD

The present disclosure relates to liquid refinement, and moreparticularly relates to removing solids and liquids from a liquidstream.

BACKGROUND

Liquid refinement is an important process for many different industries.For example, waste water treatment facilities, oil drilling operations,oil well produced water processes, fossil fuel refineries, powerstations, food processing plants, mining operations, petrochemicalplants, and agricultural operations, among others, all utilizemechanisms or systems for separating liquids from other components(e.g., contaminants, pollutants, solid particles, other liquids, etc.).Most conventional separators utilize active features (e.g., poweredelements, agitators, vibrating screens, etc.), chemical reactions,filters, and/or gravity to accomplish the desired separation. Theseparation technologies that employ active features, filter media and/orchemical reactions can be expensive and complicated to operate andmaintain. Conventional technologies that rely exclusively on gravity areeither too inefficient or are unable to achieve the requisite level ofseparation.

SUMMARY

From the foregoing discussion, it should be apparent that a need existsfor an apparatus, system, and method for refining a liquid stream thatovercome the limitations of conventional liquid separators.Beneficially, such an apparatus, system, and method would provide afaster, more complete, and higher level of separation than conventionalgravity separators, thus improving the ease, efficiency, andeffectiveness of removing components from a liquid stream.

The subject matter of the present application has been developed inresponse to the present state of the art, and in particular, in responseto the problems and needs in the art that have not yet been fully solvedby currently available liquid separators. For example, the ease,efficiency, and effectiveness of refining a liquid stream could beimproved by flowing the liquid stream across inclined plates whileslowing and redirecting the liquid stream. Accordingly, the presentdisclosure has been developed to provide apparatuses, systems, andmethods for refining a liquid stream that overcome many or all of theabove-discussed shortcomings in the art.

Disclosed herein, according to one embodiment, is an apparatus forrefining a liquid stream. The liquid stream includes a liquid carrierhaving at least one of a solid particulate and a lower density fluidmixed therein. The apparatus includes a first flow chamber, a secondflow chamber, and plates. The first flow chamber is for directing theliquid stream downwards in a first direction within the first flowchamber at a first velocity. The first flow chamber is a cone structureand the first direction is substantially parallel to gravity and thefirst velocity is greater than a settling velocity of the solidparticulate in the liquid carrier. The second flow chamber is fordirecting the liquid carrier upwards in a second direction opposite thefirst direction at a second velocity less than the settling velocity.The plates are disposed at least partially within the second flowchamber and at a transition between the first flow chamber and thesecond flow chamber. The plates have an inclined geometry to form an atleast partially laminar flow condition in the liquid stream to separatea portion of the solid particulate having a specific gravity that isgreater than a specific gravity of the liquid carrier to a lowercollection chamber and the lower density fluid and a portion of thesolid particulate having a specific gravity that is less than thespecific gravity of the liquid carrier to an upper collection reservoir.

In one implementation, one or more of the plates includes a hat disposedon an upper edge of the one or more plates to direct separated lowerdensity fluid and a portion of the solid particulate with a particlesize small enough that the particle stays suspended in the liquid streamto the upper collection reservoir. In another implementation, the hatincludes at least one of a square hat, a curved hat, and an angled hatdisposed on the upper edge of the one or more inclined plates.

In another implementation, the plates define inclined channels fluidlycoupling an outlet of the first flow chamber and an inlet of the secondflow chamber. The liquid carrier may flow into the inclined channels ina third direction perpendicular to the first and second directions. Insome implementations, the second flow chamber is a conical annulusformed around the first flow chamber. The third direction may beradially outward.

In one implementation, the plates in the transition arecircumferentially spaced apart in an annular formation. The annularformation of the plates may be positioned proximate an inlet of, andsubstantially concentric with, the second flow chamber.

In another implementation, the liquid stream does not require the use offlocculants to achieve refinement. In one implementation, the slope ofthe cone structure is about 60 degrees. Additionally, a slope of theinclined plates may be between about 20 degrees and about 70 degrees.The plates may have a geometry to apply a raking effect to push wasteradially outward on the plates. In one implementation, the inclinedplates are electrostatically charged.

In one implementation the apparatus includes at least one of a centralauger and a vibrator. The cross-sectional area of the second flowchamber may be larger than a cross-sectional area of the first flowchamber. In one implementation, the first velocity is about twice thesecond velocity. The first flow chamber and the second flow chamber arefree of moving parts. Further, the first flow chamber and the secondflow chamber are free of interchangeable media.

Also described herein is a method. The method includes directing aliquid carrier in a first direction gravitationally downward at a firstvelocity through a first flow chamber from a narrow upper portion of acone structure to a broad lower portion of the first flow chamber. Theliquid carrier includes one or more of a solid particulate and a lowerdensity fluid. The method also includes directing the liquid carrierfrom the first flow chamber into a second flow chamber in a seconddirection opposite the first direction, the second flow chambercomprising plates. The method also includes collecting a portion of thesolid particulate having a specific gravity that is greater than aspecific gravity of the liquid carrier at a lower collection chamber.The method also includes collecting the lower density fluid and aportion of the solid particulate suspended in the liquid stream. One ormore of the plates includes a hat disposed on an upper edge of the oneor more plates to direct the separated lower density fluid and theportion of the solid particulate having a specific gravity that is lowerthan the specific gravity of the liquid carrier to the upper collectionreservoir.

In one implementation, the method also includes establishing a laminarflow condition in the liquid carrier as the liquid carrier moves acrossthe plates. The plates may define inclined channels fluidly coupling anoutlet of the first flow chamber and an inlet of the second flowchamber. The method may also include directing the liquid carrier fromthe first flow chamber to the second flow chamber by moving the liquidcarrier in a third direction. The third direction may be radiallyoutward into the second flow chamber.

Also described herein is a liquid stream refining system. The systemincludes a first flow chamber, a second flow chamber, and a plate pack.The first flow chamber directs the liquid stream downwards in a firstdirection within the first flow chamber at a first velocity. The firstflow chamber is conical in geometry and the first direction issubstantially downward and parallel to gravity and the first velocity isgreater than a settling velocity of a heavier waste in a liquid carrierof the liquid stream. The second flow chamber directs the liquid carrierupwards in a second direction opposite the first direction at a secondvelocity less than the settling velocity. The plate pack includes aplurality of plates disposed in an inclined helical arrangement at leastpartially within the second flow chamber and at a transition between thefirst flow chamber and the second flow chamber. The plurality of plateshas a geometry to form an at least partially laminar flow condition inthe liquid stream to separate a portion of the heavier waste having aspecific gravity that is greater than a specific gravity of the liquidcarrier to a lower collection chamber for extraction and a lighter wastehaving a specific gravity that is less than the specific gravity of theliquid carrier to an upper collection reservoir for extraction.

Reference throughout this specification to features, advantages, orsimilar language does not imply that all of the features and advantagesthat may be realized with the present disclosure should be or are in anysingle embodiment of the disclosure. Rather, language referring to thefeatures and advantages is understood to mean that a specific feature,advantage, or characteristic described in connection with an embodimentis included in at least one embodiment of the subject matter disclosedherein. Thus, discussion of the features and advantages, and similarlanguage, throughout this specification may, but do not necessarily,refer to the same embodiment.

Furthermore, the described features, advantages, and characteristics ofthe disclosure may be combined in any suitable manner in one or moreembodiments. One skilled in the relevant art will recognize that thesubject matter of the present application may be practiced without oneor more of the specific features or advantages of a particularembodiment. In other instances, additional features and advantages maybe recognized in certain embodiments that may not be present in allembodiments of the disclosure. Further, in some instances, well-knownstructures, materials, or operations are not shown or described indetail to avoid obscuring aspects of the subject matter of the presentdisclosure. These features and advantages of the present disclosure willbecome more fully apparent from the following description and appendedclaims, or may be learned by the practice of the disclosure as set forthhereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the advantages of the disclosure will be readilyunderstood, a more particular description of the disclosure brieflydescribed above will be rendered by reference to specific embodimentsthat are illustrated in the appended drawings. Understanding that thesedrawings depict only typical embodiments of the disclosure and are nottherefore to be considered to be limiting of its scope, the subjectmatter of the present application will be described and explained withadditional specificity and detail through the use of the accompanyingdrawings, in which:

FIG. 1 is a schematic, cross-sectional view of an apparatus for removingsolid particles from a liquid stream, according to one embodiment;

FIG. 2 is a perspective view of an apparatus for removing solidparticles from a liquid stream, according to one embodiment;

FIG. 3 is a side view of the apparatus of FIG. 2, according to oneembodiment;

FIG. 4 is a cross-sectional view, as seen from reference plane A shownin FIG. 3. of the apparatus of FIG. 3, according to one embodiment;

FIG. 5 is a perspective view of the inclined plate-pack of FIG. 4,according to one embodiment;

FIG. 6 is a top view of the inclined plate-pack of FIG. 5, according toone embodiment;

FIG. 7 is a schematic flow chart diagram of a method for removing solidparticles from a liquid stream, according to one embodiment;

FIG. 8 is a schematic block diagram of a system for removing solidparticles from a liquid stream, according to one embodiment;

FIG. 9 is a schematic, cross-sectional view of an apparatus for removinga lower-density liquid from a liquid stream, according to oneembodiment;

FIG. 10 is a cross-section view of one embodiment of an apparatus forremoving a lower-density liquid from a liquid stream;

FIG. 11 is a schematic flow chart diagram of a method for removing alower-density liquid from a liquid stream, according to one embodiment;

FIG. 12 is a schematic block diagram of a system for removing alower-density liquid from a liquid stream, according to one embodiment;

FIG. 13 is a schematic, cross-sectional view of an apparatus forremoving both solid particles and a lower-density liquid from a liquidstream, according to one embodiment;

FIG. 14 is a perspective view of an apparatus for removing both solidparticles and a lower-density liquid from a liquid stream, according toone embodiment;

FIG. 15 is a side view of the apparatus of FIG. 17, according to oneembodiment;

FIG. 16 is a cross-sectional view, as seen from reference plane C shownin FIG. 18, of the apparatus of FIG. 18, according to one embodiment;

FIG. 17 is a schematic flow chart diagram of a method for removing bothsolid particles and a lower-density liquid from a liquid stream,according to one embodiment;

FIG. 18 is a schematic block diagram of a system for removing both solidparticles and a lower-density liquid from a liquid stream, according toone embodiment;

FIG. 19 is a partial cross-sectional view of an apparatus for removingheavier material and lighter material from a fluid stream, according toone embodiment;

FIG. 20 is a perspective view of an assembly of the plate pack of FIG.19 mounted on a frame;

FIG. 21 is a bottom perspective view of the plate pack of FIG. 19,according to one embodiment;

FIG. 22 is a perspective view of the plate pack of FIG. 20 without themounting frame, according to one embodiment;

FIG. 23 is a cross-sectional view of the plate pack of FIG. 22,according to one embodiment;

FIG. 24 is a side view of a cone structure, according to one embodiment;and

FIG. 25 is a schematic flow chart diagram of a method for removing bothsolid particles and a lower-density liquid from a liquid stream,according to one embodiment.

DETAILED DESCRIPTION

Reference throughout this specification to “one embodiment,” “anembodiment,” or similar language means that a particular feature,structure, or characteristic described in connection with the embodimentis included in at least one embodiment of the present disclosure. Thus,appearances of the phrases “in one embodiment,” “in an embodiment,” andsimilar language throughout this specification may, but do notnecessarily, all refer to the same embodiment. Similarly, the use of theterm “implementation” means an implementation having a particularfeature, structure, or characteristic described in connection with oneor more embodiments of the present disclosure, however, absent anexpress correlation to indicate otherwise, an implementation may beassociated with one or more embodiments.

In the following description, numerous specific details are provided.One skilled in the relevant art will recognize, however, that thesubject matter of the present application may be practiced without oneor more of the specific details, or with other methods, components,materials, and so forth. In other instances, well-known structures,materials, or operations are not shown or described in detail to avoidobscuring aspects of the disclosure.

Illustrated in FIGS. 1-18 are several representative embodiments of anapparatus for refining a liquid stream and several representativeembodiments of methods and systems of using the apparatus. Morespecifically, FIGS. 1-8 relate to an apparatus for removing solidparticles from a liquid stream, FIGS. 9-12 relate to an apparatus forremoving a lower-density liquid from a liquid stream, and FIGS. 13-18relate to an apparatus for removing both solid particles and alower-density liquid from a liquid stream.

As described herein, the apparatus for refining a liquid stream providesvarious advantages and benefits over other liquid separators and liquidseparation procedures. However, the recited advantages are not meant tobe limiting in any way, as one skilled in the art will appreciate thatother advantages may also be realized upon practicing the presentdisclosure.

FIG. 1 is a schematic, cross-sectional view of an apparatus 100 forremoving solid particles 52 from a liquid stream 50, according to oneembodiment. As mentioned above, many industrial processes require, or atleast would benefit from, the ability to efficiently and effectivelyrefine a liquid stream in order to harvest/collect elements mixedtherein and/or recycle the refined liquid. Accordingly, as usedthroughout the present disclosure, the term “liquid stream” 50 refers toa liquid carrier 51 having solid particles 52 (and/or other liquids, seebelow with reference to FIGS. 9-18) mixed into the liquid carrier 51;that is, the liquid carrier 51 is the principal constituent of theliquid stream 50 and is the medium in which the solid particles aremixed. The solid particles 52 may be suspended, dispersed, mixed,entrained, or otherwise combined with the liquid carrier 51. The solidparticles 52 have a specific gravity that is greater than the specificgravity of the liquid carrier 51. The difference between the specificgravities of the liquid carrier 51 and the solid particles 52 is a majordriving force of a successful separation. In other words, the specificgravity of the liquid carrier 51 contrasted with the specific gravity ofthe solid particles 52 yields potential energy which is exploited inorder to accomplish the separation. In one embodiment, for example, theliquid carrier 51 is water and the solid particles 52 are sediment froma drilling process. While reference is repeatedly made throughout thedisclosure to separating solid particles from the liquid carrier, theapparatus 100 may be employed to separate any substance from the liquidcarrier that has a different specific gravity from the specific gravityof the liquid carrier.

The apparatus 100 is configured to receive the liquid stream 50 througha liquid stream inlet 101 and to output collected solid particles 52through a solids outlet 102 and a refined liquid carrier 51 through aliquid carrier outlet 103. The apparatus 100 has a first flow chamber110, a second flow chamber 120, and a separation chamber 130 disposedbetween the first and second flow chambers 110, 120. The liquid stream50 enters the first flow chamber 110 and flows in a first direction 111at a first velocity. The first direction 111 is substantially parallelto gravity (i.e., downward) and the first velocity is greater than asettling velocity of the solid particles 52 in the liquid carrier 51. Inother words, the downward speed of the liquid stream 50 in the firstflow chamber 110 is greater than the speed of which the solid particles52 would fall, due to gravity, through the liquid carrier 51. Thesettling velocity of specific solid particles 52 in a specific liquidcarrier 51 can be calculated according to Stokes' law.

After passing through the first flow chamber 110, the liquid streamflows into the separation chamber 130. The separation chamber has twoportions, a redirection portion 132 and a collection portion 134. In theredirection portion 132, the flow direction of the liquid carrier 51transitions from the first direction 111 to a second direction 121opposite the first direction 111. In other words, the liquid carrier 51is redirected 180 degrees and flows upwards into the second flow chamber120. During this redirection, the liquid carrier 51 also slows from thefirst velocity to a second velocity. That is, the first velocity isdefined as the velocity of the liquid stream 50 just before undergoingthe 180 redirection in the redirection portion 132 of the separationchamber 130 and the second velocity is the velocity of the liquidcarrier 51 just after the 180-degree redirection (e.g., the velocity ofthe liquid carrier 51 entering the second flow chamber). The magnitude(i.e., speed) of the second velocity is less than the first velocity andis also less than the above discussed settling velocity of the solidparticles 52 in the liquid carrier 51. Throughout the presentdisclosure, flow directions are depicted in the figures and describedherein. These flow directions (e.g., the first flow direction 111 andthe second flow direction 121) represent an average, overall directionof flow. In other words, the flow directions shown in the figures anddescribed herein refer to macro level flow patterns. Accordingly, whilethe average or overall flow of liquid may be in the indicated direction,eddies and other forms of turbulence may cause irregularities ornon-uniformities in the micro level flow of the liquid.

The speed decrease of the liquid carrier 51, together with the180-degree redirection of the liquid carrier 51, contribute to the solidparticles 52 settling out (e.g., ‘falling out’) of the liquid carrier 51and collecting in the collection portion 134 of the separation chamber130. Thus, the apparatus 100 utilizes flow direction (e.g., the firstdirection 111 is parallel to gravity), flow redirection (e.g., changingfrom the first direction 111 parallel to gravity to the second direction121 opposite gravity), and a change in flow velocities (e.g., slowingfrom the first velocity to the second velocity) to maximize theefficiency of the gravity separation.

The cross-sectional flow area of the second flow chamber 120 can belarger than the cross-sectional flow area of the first flow chamber 110to slow the liquid carrier 51 down to the second velocity (which is lessthan or equal to the settling velocity of the solid particles 52 in theliquid carrier 51). In one embodiment, the cross-sectional area of thesecond flow chamber 120 is between about 1.5 and about 3 times largerthan the cross-sectional area of the first flow chamber 110. In oneembodiment, the first velocity is about twice the second velocity. Inone embodiment, the first velocity is such that flow of the liquidstream 50 in the first flow chamber 110 is turbulent. In anotherembodiment, the second velocity is such that flow of the liquid carrier51 in the second flow chamber 120 is laminar. The relativecross-sectional sizes of the first and second flow chambers 110, 120 canvary from application to application depending on the type of liquidcarrier 51, the type of solid particles 52, and the relative specificgravities of the liquid carrier 51 and the solid particles 52, amongother factors.

In addition to the speed decrease and the 180-degree redirection, theseparation chamber 130 of the apparatus 100 may also include aconfiguration of inclined plates 140 disposed in the fluid flow pathstarting at the end of the first flow chamber 110 and protruding somedistance below flow chamber 110 into separation chamber 130 thencontinuing up through some portion of the second flow chamber 120 thatcan include anywhere from 10% of flow chamber 120 up to 90% of flowchamber 120, depending on the desired separation efficiency. That is,the inclined plates 140 define inclined channels 249 (see FIG. 5)through which the liquid carrier 51 must flow while slowing from thefirst velocity to the second velocity and while redirecting from thefirst direction 111 to the second direction 121. The entry into theinclined plates 140 can be straight into the plates or the inside edgeof the inclined plates 140 can be bent to cause additional redirectionof the liquid carrier. Gravity pulls solid particles down so that, ifthey are large enough and heavy enough to overcome the directional flowof the liquid carrier 51 in a laminar flow condition, they hit aninclined plate. Velocity at the surface of any given inclined plate 140is negligible. Once a solid particle touches the surface of an inclinedplate 140 the particle slides down the plate into separation chamber130. Because of the circular shape of apparatus 100 the tilt and angleof the inclined plates 140 penetrating into separation chamber 130 drawor rake the particles down and toward the outside of the inclined plates140. This raking affect helps remove the particles from the flow of theliquid carrier 51 and limits re-entrainment of particles. Any solidparticles 52 that have yet to settle out of the liquid carrier 51 due tothe slowing and redirecting are promoted to settle via exposure to theextensive surface area of the inclined plates 140. Additional detailsregarding the inclined plates 140 are included below with reference toFIGS. 4-6.

According to one embodiment, the liquid carrier 51 enters (e.g., flowsinto) the configuration of inclined plates 140 sideways. In other words,the liquid carrier 51, with any remaining solid particles that have yetto settle into the collection portion 134 of the separation chamber 130,flows into the configuration of inclined plates 140 in a third direction131 that is substantially perpendicular to the first and seconddirections 111, 121. Once again, the significance of entering theinclined plates 140 in a sideways direction and other details relatingto the inclined plates 140 are included below.

The two portions 132, 134 of the separation chamber 130 are notphysically well-defined or sharply delineated. That is, these portions132, 134 of the separation chamber 130 are separately referred to hereinaccording to the predominant and distinct flow characteristics of theliquid carrier 51 and solid particles 52 in the respective portions 132,134. The liquid carrier 51 predominantly redirects in the redirectionportion 132 of the separation chamber 130 and the solid particles 52predominantly collect in the collection portion 134 of the separationchamber 130. Thus, in one embodiment, the separation chamber 130 doesnot have any physical features or barriers that distinguish the twoportions 132, 134 from each other. For this reason, the redirectionportion 132 and the collection portion 134 have been depicted in FIG. 1as somewhat amorphous shapes.

The solid particles 52 that settle into the collection portion 134 ofthe separation chamber 130 can be extracted from the apparatus 100 via asolids outlet 102. In one embodiment, the apparatus 100 can beconfigured to continuously remove settled-solid particles 52 from theseparation chamber. In another embodiment, batch-removal of the solidparticles 52 may be performed periodically or upon the determinationthat a certain amount (e.g., volume, mass, weight, etc.) of solidparticles 52 has settled in the collection portion 134 of the separationchamber 130. The solid particles 52 may be flushed, pumped, screwed, orsuctioned out, among other methods, via the solids outlet 102.

In one embodiment, the apparatus 100 is free of (i.e., does not include)any flow-affecting moving parts. For example, in one embodiment theapparatus 100 does not have any agitators or vibrating elements topromote separation. In one embodiment, the apparatus 100 does notinclude any type of flocculation subsystem. While flocculationsubsystems may be beneficial and may be included in certain embodiments,such as in applications in which the liquid carrier 51 and the solidparticles 52 form a substantially stable colloidal suspension, the abovediscussed separation efficiency of the apparatus 100 may be sufficientto achieve a desired separation level without needing flocculationsubsystems or any kind of interchangeable media. For example, theapparatus 100, without flow-affecting moving parts, flocculationsubsystems, or interchangeable media, may be able to remove solidparticles down to particle sizes ranging from about 1 micron to about 50microns. In another embodiment, the apparatus 100, withoutflow-affecting moving parts, flocculation subsystems, or interchangeablemedia, may be able to remove solid particles down to less than 25-micronparticle size. While such a result is dependent on the differencebetween the specific gravities of the carrier fluid 51 and the solid 52,such particle size separation range is generally expected when using theapparatus 100.

The second flow chamber 120 directs the liquid carrier 51, which issubstantially free of solid particles down to a certain size, upwards inthe second direction 121, continuing up through the inclined plates 140.The liquid carrier 51 can then flow out of the apparatus 100 via arefined liquid carrier outlet 103, located in the side or top ofapparatus 100 or could flow over a weir. In one embodiment, theapparatus 100 is cylindrical and flow chamber 120 forms an annulusaround flow chamber 110. For example, the first flow chamber 110 may bea central channel and the second flow chamber 120 may be an annularchannel that surrounds and is concentric with the first flow chamber110. In another embodiment, the apparatus 100 is cylindrical and flowchamber 110 is cone shaped, with flow chamber 120 forming an annulusaround the conical flow chamber 110. In either embodiment, the thirddirection 131 (i.e., the direction of the flow of the carrier fluid 51into the configuration of inclined plates 140) is radially outward.

FIGS. 2-4 illustrate various views of another embodiment of theapparatus 200 for removing solid particles 52 from the liquid stream 50.More specifically, FIG. 2 is a perspective view, FIG. 3 is a side view,and FIG. 4 is a cross-sectional view, as seen from reference plane Ashown in FIG. 3, of the apparatus 200.

The apparatus 200, which is similar to the embodiment of the apparatus100 shown in FIG. 1, has a cylindrical tank structure. The apparatus 200includes a liquid stream inlet 201 and a refined liquid carrier outlet203. In the depicted embodiment, the liquid stream inlet 201 and therefined liquid carrier outlet 203 are disposed on opposite sides of theapparatus 200. The apparatus 200 also includes multiple ports 202, 299,298 disposed near the bottom of the apparatus 200. The port at thebottom of the apparatus 200 is the solid outlet 202. The solid particlesthat fall out of the liquid carrier and collect in a bottom portion 206of the apparatus 200 can be removed from the apparatus 200 via the solidoutlet 202 by gravity flow, pressure from an inlet pump, pressure from apump independent of the inlet pumps, and/or a screw mechanism. The otherports 299, 298 are used for various types of instruments that can detectthe level of the solids accumulating in the bottom portion 206 of theapparatus. In one embodiment, the lower port 299 is used for a tuningfork or similar instrument that measures denser particles. The higherport 298 may be another density detection device that measures lowerdensity solids that settle out slower or may form in a “rag layer” in anupper area of the bottom portion 206, just below the inclined plates240.

In the depicted embodiment, the housing of the apparatus 200 includes anupper portion 204 and a lower portion 206 that are detachably coupledtogether. As described below, the detachable coupling between the upperand lower portions 204, 206 allows easy access to the interior of theapparatus 200 for maintenance, repair, etc. The upper portion 204 has anupper flange 205 that couples to a corresponding lower flange 207 of thelower portion 206. Fasteners 208, such as bolts and nuts, may beemployed to securely hold the two portions 204, 206 together. In oneembodiment, as shown in FIGS. 4-6, the configuration of inclined plates240 may have an external flange 243 that is sandwiched between the upperand lower flanges 205, 207 of the housing of the apparatus 200. In suchan embodiment, the fasteners 208 that hold the two portions 204, 206 ofthe housing together also serve to secure the configuration of theinclined plates 240. In certain applications, it may be beneficial forthe inclined plates 140 (i.e., the “plate pack” 140) to be removablefrom the apparatus 200, thereby enabling a user to swap out plate packs,repair plate packs, or clean plate packs, etc. In other embodiments, theinclined plates 240 may be held in place using an internal structureattached to flow chamber 210 or they may be attached to flow chamber 210with clips or tabs or may be welded to flow chamber 210.

The apparatus 200 is configured to receive the liquid stream 50 througha liquid stream inlet 201 disposed on one side of the upper portion 204of the apparatus 200. The liquid stream 50 flows through a pipe to thefirst flow chamber 210, which is the central chamber of the apparatus200. The liquid stream 50 flows out of the inlet pipe through an inlet212 of the first flow chamber 210. The liquid stream 50 in the firstflow chamber 210 flows in the first direction 211 at the first velocity.Once again, the first direction 211 is substantially parallel to gravity(i.e., downward) and the first velocity is greater than the settlingvelocity of the solid particles 52 in the liquid carrier 51.

After passing through the first flow chamber 210, the liquid carrier 51flows into the separation chamber 230. The separation chamber 230 hasthe redirection portion 232 and the collection portion 234. In theredirection portion 232, the flow direction of the liquid carrier 51transitions from the first direction 211 to the second direction 221.The cross-sectional flow area of the second flow chamber 220 is largerthan the cross-sectional flow area of the first flow chamber 210 to slowthe liquid carrier 51 down to the second velocity (which is less than orequal to the settling velocity of the solid particles 52 in the liquidcarrier 51).

The inclined plates 240 are disposed in the separation chamber 230 andfluidly couple an outlet 214 of the first flow chamber 210 and an inlet222 of the second flow chamber 220. FIGS. 5 and 6 show views of theannular formation of the inclined plates 240 removed from the housing ofthe apparatus 200. More specifically, FIG. 5 is a perspective view ofthe annular formation of the inclined plates 240 and FIG. 6 is a topview of the annular formation of inclined plates 240, according to oneembodiment.

In the depicted embodiment, the inclined plates 240 are disposed in theredirection portion 232 of the separation chamber 230 and arecircumferentially spaced apart in an annular formation. The inclinedplates 240 are secured together in the annular formation (e.g., insteadof being loose and independently movable). The annular formation ofinclined plates 240 is held together, as a unit, by ‘ring flanges’. Inother words, the annular formation of the inclined plates 240 has anexternal flange 243 and one or more internal flanges. In the depictedembodiment, the annular formation of inclined plates 240 has twointernal flanges 241, 242. The individual plates are mounted between theexternal flange 243 and the internal flanges 241, 242. The externalflange 243, as described above, engages the upper and lower flanges 205,207 of the housing of the apparatus 200 to secure the position of theannular formation of the inclined plates 240 within the apparatus 200.The first internal flange 241 of the inclined plates 240 is positionedhigher (relative to the gravity vector) than the external flange 243 andthe second internal flange 242 is positioned lower than the externalflange 243 (e.g., see FIG. 4). Such a configuration yields a unit ofinclined plates 240 that has structural rigidity. In another embodiment,the inclined plates 240 can be supported by bands around the exterior ofthe inclined plates 240 that are attached to the plates with tabs and/orby welding. In another embodiment, the inside of the inclined plates 240can be supported by attaching the inclined plates 240 directly to aninternal cylinder or cone with either tabs and/or welding instead ofusing rings 241, 242.

The annular formation of inclined plates 240 is positioned proximate theinlet 222 of, and substantially concentric with the annulus that is, thesecond flow chamber 220. In one embodiment, the inclined plates 240extend partially or completely into the second flow chamber 220. Thatis, a portion of the inclined plates 240 extends beyond the inlet 222 ofthe second flow chamber 220. Higher surface area may improve the degreeof separation that is achieved by extending the surface area of theinclined plates 240 above the outlet 214 of the first flow chamber 210.

In another embodiment, more than half or even up to all of the height ofthe annular formation of the inclined plates 240 extends above theexternal flange 243. Said differently, a major portion of the annularformation of inclined plates 240 extends above the external flange 243while a minor portion extends below the external flange 243. In such aconfiguration, a greater portion of the total height of the annularformation of inclined plates 240 extends into the upper portion 204 ofthe apparatus 200 than the lower portion 206 of the apparatus 200. Asmentioned above, the lower portion 206 of the apparatus 200 may have aconical shape that helps to funnel the settling solid particles 52B tothe very bottom of the apparatus 200 for extraction via the solidsoutlets 202. In one embodiment, the annular formation of the inclinedplates 240 extends partially into the conical section of the lowerportion 206 of the apparatus 200. As shown in FIG. 4, and according toone embodiment, the internal diameter of the annular formation of theinclined plates 240 is narrowest between the first and second internalflanges 241, 242.

The space between adjacent inclined plates, defined above as inclinedchannels 249 (e.g., see FIG. 5), may be dependent on the specifics of agiven application. For example, the spacing between the inclined plates240 may be dependent on the concentration of solid particles in theliquid carrier and/or the average expected size of the solid particles.In one embodiment, the spacing between adjacent inclined plates (i.e.,the thickness of the inclined channels 249) is between about 0.25 inchesand about 1 inch. In another embodiment, the spacing between adjacentinclined plates is about 0.5 inches. In one embodiment, the spacingbetween adjacent plates is uniform throughout the annular formation.

In one embodiment, the spacing between adjacent plates is less thanconventional plate-type clarifiers. For example, conventional plate-typeclarifiers may experience plugging or clogging because the entire flowof the liquid stream, or at least a major extent of the flow of theliquid stream, is channeled directly towards the plates in conventionalclarifiers and/or conventional clarifiers do not incorporate a180-degree redirection aligned with gravity or a decrease in velocity.In other words, the apparatus 200 of the present disclosure isespecially effective and efficient because, according to the embodimentdepicted in FIG. 4, the larger, denser solid particles 52A flow rightthrough the center core of the annular formation of the inclined plates240 without flowing in the third direction 231 into the inclinedchannels 249 defined by the inclined plates 240. Because the largestand/or most dense solid particles do not pass across the inclined plates240, the annular formation of inclined plates 240 is comparatively lessprone to clogging and plugging.

As mentioned above, the smaller, less dense solid particles 52B flowsideways (e.g., flow in the third direction 231) with the liquid carrier51 across the inclined plates 240 (i.e., into and through the channels249). By entering the inclined channels in a substantially sidewaysdirection 231, the plate separation process is not working directlyagainst gravity (e.g., like some conventional up-flow clarifiers). Inone embodiment, the size and dimension of the annular formation of theinclined plates 240 is such that a gap 238 is left between the externalperimeter of the annular formation of the inclined plates 240 and theinner sidewalls of the separation chamber 230. Because the liquidcarrier 51 enters the channels 249 sideways 231, any solid particlesthat remain entrained with the liquid carrier 51 after crossing theinclined plates 240 will catch on the edge and be directed downwardtowards the collection portion 234 through the gap 238.

In one embodiment, the slope of the inclined plates 240, relative tohorizontal, is between about 20 degrees and about 70 degrees. In anotherembodiment, the slope of the inclined plates 240, relative tohorizontal, is about 55 degrees. As mentioned above, where conventionalclarifiers may experience plugging or clogging, the apparatus 200 of thepresent disclosure may allow for a comparatively wider range of possibleslopes for the inclined plates 240. In another embodiment, as shown inFIG. 6, the inclined plates 240 are not only inclined relative tohorizontal, but the inclined plates 240 are also angled relative to aradius 244 of the annular formation of inclined plates 240. That is, theinclined plates 240 are not aligned parallel with radii of the annularformation, but instead are offset from the radii of the annularformation. The angle effect of the circular shape of the annularformation draws or rakes the particles down and toward the outside ofthe inclined plates 140. This raking affect helps remove the particlesfrom the flow of the liquid carrier 51 and limits re-entrainment ofparticles.

In one embodiment, the inclined plates may be electrostatically chargedto further promote separation. In yet another embodiment, certain edgesof the plates 240 may be bent to facilitate settling of the solidparticles. As mentioned above, the apparatus 200 may be free of (i.e.,does not include) any flow-affecting moving parts. For example, in oneembodiment the apparatus 200 does not have any agitators or vibratingelements to promote separation.

While most of the figures of the present disclosure depicted cylindricalembodiments of the apparatus 200, it is expected that the apparatus canhave other shapes or structures. Additionally, the apparatus 200 can bebuilt from any type of metal, composite, and/or plastic material. Thelower portion 206 of the apparatus 200, as mentioned above, may beconical in shape at any angle to facilitate collection of the solidparticles. The steeper the angle, the faster that particles will slideinto the cone and the thicker the solids will become in the bottom ofthe collection chamber 234. In another embodiment, the lower portion 206may be dish-shaped or semi-circular. The upper portion 204 may be flat,dished, coned, flanged, or welded. In another embodiment, the flowchamber 210 can be conical or bell shaped. The apparatus 200 can beoperated at atmospheric conditions or under pressure. The size anddimensions of the apparatus may be tailored for a specific application.

FIG. 7 is a schematic flow chart diagram of a method 280 for removingsolid particles from a liquid stream, according to one embodiment. Theliquid stream includes a liquid carrier that has solid particles mixedtherein. The solid particles have a specific gravity that is greaterthan the specific gravity of the liquid carrier. The method 280 includesflowing the liquid stream through a first flow chamber in a firstdirection at a first velocity at 281. The first direction issubstantially parallel to gravity and the first velocity is greater thana settling velocity of the solid particles in the liquid carrier. Themethod 280 further includes redirecting the liquid carrier 180 degreessuch that the liquid carrier flows into a second flow chamber in asecond direction opposite the first direction at a second velocity lessthan the settling velocity at 282. During redirecting the liquidcarrier, the liquid carrier flows into inclined channels at 283, whichare defined by inclined plates and fluidly couple an outlet of the firstflow chamber and an inlet of the second flow chamber, in a thirddirection substantially perpendicular to the first and seconddirections. The method 280 also includes collecting the solid particlesas the solid particles fall out of the liquid carrier during redirectingthe liquid carrier at 284.

In one embodiment, the method includes electrostatically charging theinclined plates. In another embodiment, the first velocity is abouttwice the second velocity.

FIG. 8 is a schematic block diagram of a system 290 for removing solidparticles from a liquid stream 50, according to one embodiment. Thesystem 290 shows how the apparatus 100, 200 might be used in a treatmentsystem that includes a first clarifier 291 (apparatus 100,200) Thesystem also includes a chemical treatment subsystem 293 that receivesand disinfects the liquid carrier 51 from the first clarifier 291 and afilter 292 that receives and further clarifies the liquid carrier 51from the first clarifier subsystem 291. In one embodiment, the filter292 receives the refined liquid carrier 51 from the first clarifier 291before the chemical treatment subsystem 293. In another embodiment, thechemical treatment subsystem 293 receives the refined liquid carrier 51from the first clarifier 291 before the filter 292. Regardless theorder, the filtered liquid carrier 54 and the chemically treated liquidcarrier 55 constitute a refined liquid stream. In one embodiment, thesystem 290 further includes one or more of the following: a pHadjustment subsystem, a de-emulsifier subsystem, a desalinationsubsystem, and a flocculant subsystem.

FIG. 9 is a schematic, cross-sectional view of the apparatus 300 forremoving a lower-density liquid 62 from a liquid stream 60, according toone embodiment. The depicted embodiment of the apparatus 300 is similarin concept to the previously described embodiments with regard to a180-degree redirection, a decreased flow velocity, and inclined plates.However, the apparatus 300 of FIG. 9 is utilized for separating alower-density liquid 62 from a liquid carrier 61.

As mentioned above, the lower-density liquid 62 refers to a liquid thathas a specific gravity that is less than the specific gravity of theliquid carrier 61. The difference between the specific gravities of theliquid carrier 61 and the lower-density liquid 62 is a major drivingforce of a successful separation. In other words, the specific gravityof the liquid carrier 61 contrasted with the specific gravity of thelower-density liquid 62 yields potential energy which is exploited inorder to accomplish the separation. In one embodiment, for example, theliquid carrier 61 is water and the lower-density liquid 62 is oil orother hydrocarbons.

The apparatus 300 is configured to receive the liquid stream 60 througha liquid stream inlet 301 and to output collected lower-density liquid62 through a lower-density liquids outlet 309 and a refined liquidcarrier 61 through a liquid carrier outlet 303. The apparatus 300 has afirst flow chamber 310, a second flow chamber 320, and a separationchamber 330 disposed between the first and second flow chambers 310,320. The liquid stream 60 enters the first flow chamber 310 and flowsthrough the first flow chamber 310 in a first direction 311. Thevelocity of the liquid stream 60 upon exiting the first flow chamber 310is referred to as the first velocity. The first direction 311 isopposite gravity (i.e., upwards) and the first velocity is greater thana rise-velocity of the lower-density liquid 62 in the liquid carrier 61.In other words, the upward speed of the liquid stream 60 in the firstflow chamber 310 is greater than the speed of which the lower-densityliquid 62 would rise, due to buoyancy, through the liquid carrier 61.The rise-velocity of specific lower-density liquid droplets 62 in aspecific liquid carrier can be calculated according to Stokes' law.

After passing through the first flow chamber 310, the liquid streamflows into the separation chamber 330. The separation chamber 330 hastwo portions, a redirection portion 332 and a collection portion 334. Inthe redirection portion 332, the flow direction of the liquid carrier 61transitions from the first direction 311 to a second direction 321opposite the first direction 311. In other words, the liquid carrier 61is redirected 180 degrees and flows downwards into the second flowchamber 320. During this redirection, the liquid carrier 61 also slowsfrom the first velocity to a second velocity. The magnitude (i.e.,speed) of the second velocity is less than the first velocity and isalso less than the above discussed rise-velocity of the lower-densityliquid 62 in the liquid carrier 61.

The speed decrease of the liquid carrier 61, together with the180-degree redirection of the liquid carrier 61, contribute to thelower-density liquid 62 rising out of the liquid carrier 61 andcollecting in the collection portion 334 of the separation chamber 330.Thus, the apparatus 300 utilizes flow direction (e.g., the firstdirection 311 is opposite to gravity), flow redirection (e.g., changingfrom the first direction 311 opposite gravity to the second direction321 parallel to gravity), and a change in flow velocities (e.g., slowingfrom the first velocity to the second velocity) to maximize theefficiency of the gravity separation.

The cross-sectional flow area of the second flow chamber 320 is largerthan the cross-sectional flow area of the first flow chamber 310 to slowthe liquid carrier 61 down to the second velocity (which is less than orequal to the rise-velocity of the lower-density liquid 62 in the liquidcarrier 61). In one embodiment, the cross-sectional area of the secondflow chamber 320 is between about 1.5 and about 3 times larger than thecross-sectional area of the first flow chamber 310. In one embodiment,the first velocity is about twice the second velocity. In oneembodiment, the first velocity is such that flow of the liquid stream 60in the first flow chamber 310 may be turbulent or laminar. In anotherembodiment, the second velocity is such that flow of the liquid carrier61 in the second flow chamber 320 is always laminar. The relativecross-sectional sizes of the first and second flow chambers 310, 320 canvary from application to application depending on the type of liquidcarrier 61, the type of lower-density liquid 62, and the relativespecific gravities of the liquid carrier 61 and the lower-density liquid62, among other factors.

In addition to the speed decrease and the 180-degree redirection, theseparation chamber 330 of the apparatus 300 may also include aconfiguration of inclined plates 340 disposed in the fluid flow pathstarting at the end of the first flow chamber 310 and protruding somedistance above flow chamber 310 into separation chamber 330 thencontinuing down through some portion of the second flow chambers 320that can include anywhere from about 10% of flow chamber 320 up to about90% of flow chamber 320, depending on the desired separation efficiency.That is, the inclined plates 340 define inclined channels (e.g., similarto the inclined channels 249 in FIG. 5) through which the liquid carrier61 must flow while slowing from the first velocity to the secondvelocity and while redirecting from the first direction 311 to thesecond direction 321. The entry into the inclined plates 340 can bestraight into the plates or the inside edge of the inclined plates 340can be bent to cause additional redirection of the liquid carrier 61.Buoyance lifts lighter particles up so that if they are large enough andlight enough to overcome the directional flow of the liquid carrier 61in a laminar flow condition they hit an inclined plate. Velocity at thesurface of any given inclined plate 340 is negligible. Once a solidparticle touches the surface of an inclined plate 340 the particleslides up the plate into separation chamber 330. Because of the circularshape of apparatus 300 the tilt and angle of the inclined plates 340penetrating into separation chamber 330 draw or rake the particles upand toward the outside of the inclined plates 340. This raking affecthelps remove the particles from the flow of the liquid carrier 61 andlimits re-entrainment of particles. Any lower-density liquid droplets 62that have yet to rise out of the liquid carrier 61 due to the slowingand redirecting are allowed to settle via exposure to the extensivesurface area of the inclined plates 340. The inclined plates 340 may besubstantially similar to the inclined plates 240 described above withreference to FIGS. 4-6.

According to one embodiment, the liquid carrier 61 enters (e.g., flowsinto) the configuration of inclined plates 340 sideways. In other words,the liquid carrier 61, with any remaining lower-density liquid dropletsthat have yet to rise into the collection portion 334 of the separationchamber 330, flows into the configuration of inclined plates 340 in athird direction 331 that is substantially perpendicular to the first andsecond directions 311, 321.

The two portions 332, 334 of the separation chamber 330 are notphysically well-defined or sharply delineated. That is, these portions332, 334 of the separation chamber 330 are separately referred to hereinaccording to the predominant and distinct flow characteristics of theliquid carrier 61 and lower-density liquid 62 in the respective portions332, 334. The liquid carrier 61 predominantly redirects in theredirection portion 332 of the separation chamber 330 and thelower-density liquid 62 predominantly collects in the collection portion334 of the separation chamber 330. Thus, in one embodiment, theseparation chamber 330 does not have any physical features or barriersthat distinguish the two portions 332, 334 from each other. For thisreason, the redirection portion 332 and the collection portion 334 havebeen depicted in FIG. 1 as somewhat amorphous shapes.

The lower-density liquid 62 that rises into the collection portion 334of the separation chamber 330 can be extracted from the apparatus 300via a lower-density liquid outlet 309. In one embodiment, the apparatus300 can be configured to continuously remove lower-density liquid 62from the separation chamber 330. In another embodiment, batch-removal ofthe lower-density liquid 62 may be performed periodically or upon thedetermination that a certain amount (e.g., volume, mass, weight, etc.)of lower-density liquid 62 has settled in the collection portion 334 ofthe separation chamber 330. The lower-density liquid may be flushed,pumped, or suctioned out, among other methods, via the lower-densityliquid outlet 309.

In one embodiment, the apparatus 300 is free of (i.e., does not include)any flow-affecting moving parts. For example, in one embodiment theapparatus 300 does not have any agitators or vibrating elements topromote separation.

The second flow chamber 320 directs the liquid carrier 61, which issubstantially free of lower-density liquid down to a certain size,downwards in the second direction 321, continuing downward through theinclined plates 340. In one embodiment, the apparatus 300 removeshydrocarbons down to a droplet size ranging from about 5 microns toabout 100 microns, depending on various factors, including the specificgravity differential, particle size, temperature, viscosity, and flowrate (e.g., Stokes' Law variables). The liquid carrier 61 can then flowout of the apparatus 300 via a refined liquid carrier outlet 303. In oneembodiment, the apparatus 300 is cylindrical and one of the two flowchambers 310, 320 forms an annulus around the other. For example, thefirst flow chamber 310 may be a central channel and the second flowchamber 320 may be an annular channel that surrounds and is concentricwith the first flow chamber 310. In another embodiment, the apparatus300 is cylindrical and flow chamber 310 is cone shaped, with flowchamber 320 forming an annulus around the conical flow chamber 310. Ineither embodiment, the third direction 331 (i.e., the direction of theflow of the carrier fluid 61 into the configuration of inclined plates340) is radially outward.

FIG. 10 is a cross-section view of one embodiment of the apparatus 400for removing the lower-density liquid from the liquid stream. Similarand analogous to the schematic depiction of FIG. 9, the embodiment ofthe apparatus 400 in FIG. 10 has a first flow chamber 410 that receivesthe liquid stream from the liquid stream inlet 401. The first flowchamber 410 directs flow in an upwards direction. Upon exiting the firstflow chamber, the liquid carrier flows across multiple inclined plates440 disposed in the redirection portion 432 of the separation chamber430. As the liquid stream flows across the inclined plates 440, thelower-density liquid separates from the liquid carrier. The separatedlower-density liquid collects in the collection portion 434 of theseparation chamber 430. The liquid carrier flows out of theconfiguration of inclined plates 440 and enters the second flow chamber420. The refined liquid carrier flows in a downward direction throughthe second flow chamber 420.

In the depicted embodiment, the apparatus 400 has top and bottom heads418, 419 that are flat. In other embodiments, the top and bottom heads418, 419 can be torispherical, elliptical, conical, hemispherical, etc.In one embodiment, the apparatus 400 has coalescing media disposed inone or both of the first and second flow chambers 410, 420. Thecoalescing media may polypropylene, polyethylene, or some other type ofcoalescing-inducing material.

FIG. 11 is a schematic flow chart diagram of a method 480 for removing alower-density liquid from a liquid stream, according to one embodiment.The liquid stream includes a liquid carrier having a lower-densityliquid mixed therein and the lower-density liquid has a specific gravitythat is less than a specific gravity of the liquid carrier. The method480 includes flowing the liquid stream through a first flow chamber in afirst direction at a first velocity at 481. The first direction issubstantially opposite gravity and the first velocity is greater than arise-velocity of the lower-density liquid in the liquid carrier. Themethod 480 further includes redirecting the liquid carrier 180 degreessuch that the liquid carrier flows through a second flow chamber in asecond direction opposite the first direction at a second velocity lessthan the rise-velocity at 482. The method 480 further includes flowingthe liquid carrier out of inclined channels in a third directionsubstantially perpendicular to the first and second directions at 483.The inclined channels are defined by inclined plates and fluidly couplean outlet of the first flow chamber and an inlet of the second flowchamber. The method 480 further includes collecting the lower-densityliquid as the lower-density liquid rises out of the liquid carrierduring redirecting the liquid carrier at 484.

In one embodiment, the method includes electrostatically charging theinclined plates. In another embodiment, the first velocity is abouttwice the second velocity.

FIG. 12 is a schematic block diagram of a system 490 for removing alower-density liquid from a liquid stream 60, according to oneembodiment. The liquid stream includes a liquid carrier having alower-density liquid mixed therein. The lower-density liquid has aspecific gravity that is less than a specific gravity of the liquidcarrier. The system 490 shows how the apparatus 300, 400, 500 might beused in a treatment system that includes a first clarifier 491(apparatus 300, 400, 500). The system 490 also includes a chemicaltreatment subsystem 493 and a filter 492. In one embodiment, the filter492 receives the refined liquid carrier 61 from the first clarifier 491before the chemical treatment subsystem 493. In another embodiment, thechemical treatment subsystem 493 receives the refined liquid carrier 61from the first clarifier 491 before the filter 492. Regardless theorder, the filtered liquid carrier 64 and the chemically treated liquidcarrier 65 constitute a refined liquid stream. In one embodiment, thesystem 490 includes at least one of the following: a pH adjustmentsubsystem, a de-emulsifier subsystem, a desalination subsystem, and acoalescing subsystem. Further, the system 490 may include backwash mediaand/or a polishing filter. These components may be able to reducehydrocarbons down to the parts per billion ranges.

FIG. 13 is a schematic, cross-sectional view of an apparatus 500 forremoving both solid particles 72 and a lower-density liquid 73 from aliquid stream 70, according to one embodiment. The depicted apparatus500 combines concepts from the solid-separator apparatus of FIGS. 1-8with concepts from the liquid-separator of FIGS. 9-12. The depictedapparatus 500 includes three flow chambers 510, 520, 550, two separationchambers 530, 535, and two formations of inclined plates 540, 545. Inone embodiment, as depicted in FIG. 13, the inlet pipe is the first flowchamber 510. However, in another embodiment, as depicted in FIG. 16, theinlet pipe 699 is not the first flow chamber 710 but instead the inletpipe 699 delivers the liquid stream to the first flow chamber 710. Inother words, the first flow chamber is defined as the flow compartmentjust before the 180-degree redirection.

The liquid stream 70 enters the apparatus at a liquid stream inlet 501and flows into the first flow chamber 510 in a first direction 511 at afirst velocity. The first direction 511 is parallel to gravity. Thefirst velocity is greater than a settling velocity of the solidparticles 72 in the liquid carrier 71. Upon exiting the first flowchamber 510, the liquid carrier 71 enters a bottom separation chamber530. The liquid carrier 71 slows to a second velocity and transitions toflow in a second direction 521 opposite gravity. During slowing andredirection, the liquid carrier 71 flows in a third direction 531perpendicular to the first and second directions 511, 521 into a bottomformation of inclined plates 540. Solid particles 72 in a redirectionportion 532 of the separation chamber 530 settle out of the liquidcarrier 71 and collect in a collection portion 534 of the separationchamber 530.

After passing through the bottom separation chamber 530 and the bottomformation of inclined plates 540, the liquid carrier 71A, nowsubstantially free of solid particles down to a certain size, flows inthe second direction 521 (e.g., upwards) through a second flow chamber520 at the second velocity. The second velocity is less than thesettling velocity of the solid particles 72. In one embodiment, thediameter of the center chamber (e.g., the third flow chamber 550)increases in the second direction 521, thus narrowing, in the seconddirection 521, the cross-sectional dimension of the second flow chamber520 to increase the flow velocity in the second flow chamber back to thefirst velocity.

In one embodiment, the liquid carrier 71A flows out of the second flowchamber 520 at a third velocity and into a top formation of inclinedplates 545 and a top separation chamber 535. In an alternativeembodiment, the top inclined plates 545 may be omitted if the extrasurface area of the top inclined plates 545 is not necessary to achievea desired degree of separation. Regardless of whether the top inclinedplates 545 are included, the liquid carrier 71A experiences a 180-degreeredirection and transitions from the third velocity to a fourthvelocity. The third velocity is defined herein as the velocity of theliquid carrier 71A flowing out of the second flow chamber 520 and thefourth velocity is defined herein as the velocity of the liquid carrier71B flowing into the third flow chamber 550. In one embodiment, thesecond velocity (velocity into the second flow chamber) is the same asthe third velocity (velocity out of the second flow chamber).

If the cross-sectional dimension of the second flow chamber 520 changesfrom the inlet to the outlet, the second velocity would not be the sameas the third velocity. For example, if the cross-sectional dimension ofthe second flow chamber narrows (e.g., via tapering or a steptransition), the magnitude third velocity may be substantially the sameas the magnitude of the first velocity. That is, the liquid carrier 71Acan speed back up to the magnitude of the first velocity so that theliquid enters both 180 redirections at substantially the same speed.Regardless of whether the second flow chamber undergoes a change incross-sectional dimension, the first velocity (i.e., the velocity of theliquid carrier upon entering the first redirection (e.g., the bottomseparation chamber 530) is greater than settling velocity of the solidparticles in the liquid carrier. Also, the second velocity (e.g., thevelocity of the liquid carrier exiting the first redirection (e.g., thebottom separation chamber 530) is less than the settling velocity of thesolid particles in the liquid carrier. The same is true for the thirdand fourth velocities and the second redirection (e.g., the topseparation chamber 535) with reference to the rise velocity of thelower-density liquid in the liquid carrier. That is, the third velocity(e.g., the velocity of the liquid carrier entering the top separationchamber) 535 is greater than the rise velocity while the fourth velocity(e.g., the velocity of the liquid carrier exiting the separation chamber535) is less than the rise velocity. The liquid carrier 71A exits thetop formation of inclined plates 545 in a fourth direction 536substantially perpendicular to the first and second directions 511, 521.In one embodiment, the third and fourth directions 531, 536 aresubstantially opposite. That is, the third direction 531 is radiallyoutward and the fourth direction 536 is radially inward.

The redirection and slowing of the liquid carrier in the redirectionportion 537 of the top separation chamber 535, in conjunction with theflow of the liquid carrier through channels defined by the top formationof inclined plates 545, facilitates the separation of the lower-densityliquid 73 from the liquid carrier. The lower-density liquid 73accumulates in the collection portion 539 of the top separation chamber535. The liquid carrier 71B, now substantially free of both solidparticles 72 and lower-density liquid 73, flows in the first direction511 (e.g., downwards) in the third flow chamber 550 at the fourthvelocity that is less than the third velocity and that is less than therise-velocity of the lower-density liquid 73 in the liquid carrier. Therefined liquid carrier 71B flows out of the apparatus via a refinedliquid carrier outlet 503.

In one embodiment, the second flow chamber 520 includes coalescing mediato facilitate the separation of the lower-density liquid 73 from theliquid carrier. According to another embodiment, the second flow chamber520 is annulus formed around the third flow chamber 550. Additionaldetails relating to the apparatus 500 of FIG. 13 can be found above withreference to the similar and analogous embodiments described above. Forexample, the first and second flow chambers 510, 520, the bottomseparation chamber 530, and the bottom inclined plates 540 are analogousto the first and second flow chambers 110, 120, the separation chamber130, and the inclined plates 140 of FIG. 1, respectively. Also, thesecond and third flow chambers 520, 550, the top separation chamber 535,and the top inclined plates 545 are analogous to the first and secondflow chambers 310, 320, the separation chamber 330, and the inclinedplates 340 of FIG. 9, respectively.

FIGS. 14-16 illustrate views of one embodiment of the apparatus 700 forremoving both solid particles and a lower-density liquid from a liquidstream 70. In the depicted embodiment, two formations of inclined platesare included in the apparatus 700 to maximize the surface area of theinclined plates in order to maximize the separating power of theapparatus. More specifically, FIG. 14 is a perspective view, FIG. 15 isa side view, and FIG. 16 is a cross-sectional view, as seen fromreference plane C shown in FIG. 15, of the apparatus 700, according toone embodiment. The depicted apparatus 700 is similar to the apparatusshown and described with reference to FIG. 13. The apparatus 700includes three flow chambers 710, 720, 750, two separation chambers 730,735, and two annular formations of inclined plates 740, 745. In analternative embodiment, the apparatus may only include the bottomformation of inclined plates 740 and the top formation of inclinedplates 745 may be omitted. For example, in certain applications theextra surface area of the top inclined plates 745 may not be required toachieve the necessary level of separation. That is, in one embodimentthe bottom inclined plates 740, in conjunction with the second180-degree redirection, may sufficiently separate the lower-densityliquid from the liquid carrier.

The liquid stream 70 enters the apparatus at a liquid stream inlet 701and flows through an inlet pipe 699. In another embodiment the inletpipe 699 could enter through the apparatus 700 at any location as longas it ends at the same place just below separator plate 755. A separatorplate 755 at the bottom of the third flow chamber 750 separates thethird flow chamber 750 from the first flow chamber 710. After passingthrough the separator plate 755, the inlet pipe 699 outputs the liquidstream either straight down into the first flow chamber 710 (similar toFIG. 12) or the inlet pipe 699 includes a u-bend that turns the liquidstream 70 back in an upwards direction towards the separator plate 755(as shown in FIG. 16). The outlet of the inlet pipe 699 is the inlet 712of the first flow chamber 710. Accordingly, the liquid stream exits theinlet pipe 699 in an upwards direction and contacts the underside of theseparator plate 755. After hitting the underside of the separator plate755, the liquid stream flows downward in a first direction 711 parallelto gravity at a first velocity. Thus, while the overall and averagedirection of the flow of the liquid stream 70 in the first flow chamber710 is in the first direction 711 (i.e., downward), the local, microlevel flow direction of the liquid stream 70 immediately upon exitingthe inlet pipe 699 is in an upwards direction, according to oneembodiment. This local, micro level upwards flow causes the liquidstream 70 to strike the underside of the separator plate 755, therebycreating an even distribution across the flow chamber 710.

The first velocity is greater than the settling velocity of the solidparticles 72 in the liquid carrier 71. Upon exiting the first flowchamber 710, the liquid carrier 71 enters a bottom separation chamber730. The liquid carrier 71 slows to a second velocity and transitions toflow in a second direction 721 opposite gravity. During slowing andredirection, the liquid carrier 71 flows in a third direction 731perpendicular to the first and second directions 711, 721 into a bottomformation of inclined plates 740. Solid particles 72 in a redirectionportion 732 of the separation chamber 730 settle out of the liquidcarrier 71 and collect in a collection portion 734 of the separationchamber 730. As described above with reference to FIGS. 2-4, theapparatus 700 includes multiple ports 702, 799, 798 disposed near thebottom of the apparatus 700. The port at the bottom of the apparatus 700is the solid outlet 702. The solid particles that collect in thecollection portion 734 can be removed from the apparatus 700 via thesolid outlet 702 by gravity flow, pressure from an inlet pump, pressurefrom a pump independent of the inlet pumps, and/or a screw mechanism.The other ports 799, 798 can be used for various types of instrumentsthat can detect the level of the solids accumulating in the collectionportion 734. In one embodiment, the lower port 799 is used for a tuningfork or similar instrument that measures denser particles. The higherport 798 may be another density detection device that measures lowerdensity solids that settle out slower or may form in a “rag layer” in anupper area of the collection portion 734, just below the inclined plates740.

After passing through the bottom separation chamber 730 and the bottomformation of inclined plates 740, the liquid carrier 71A, nowsubstantially free of solid particles down to a certain size, flows intothe second direction 721 (e.g., upwards) at the second velocity andflows through the second flow chamber 720. In one embodiment, as theliquid carrier flows through the second flow chamber 720, thecross-sectional dimension of the second flow chamber 720 decreases sothat the third velocity (e.g., the velocity of the liquid carrier 71Aexiting the second flow chamber and flowing into the top separationchamber) is greater than the second velocity. That is, the velocity ofthe liquid carrier 71A increases by the time the liquid carrier 71Areaches the top of the second flow chamber 720. In one embodiment, thechange in the cross-sectional dimension of the second flow chamber 720may be directly correlated with the diameter of the central chamber(i.e., the third flow chamber 750). In one embodiment, as describedabove, the third velocity may have the same magnitude as the firstvelocity. The third velocity is greater than a rise-velocity of thelower-density liquid 73 in the liquid carrier 71A and the fourthvelocity is less than the rise-velocity of the lower-density liquid 73in the liquid carrier 71B.

The liquid carrier 71A flows out of the second flow chamber 720 andundergoes a second 180-degree redirection. As described above, thesecond 180 direction may include the top formation of inclined plates745 shown in FIG. 16 or the top formation of inclined plates 745 may beomitted. That is, in certain implementations where the extra surfacearea of the top inclined plates is not necessary to achieve theliquid-liquid separation, the 180-degree redirection between the second720 and third flow chambers 750 may sufficiently separate thelower-density liquid from the liquid carrier. It is also possible thatthe diameter of the center pipe does not transition and stays the same.

In the depicted embodiment, the liquid carrier 71A exits the topformation of inclined plates 745 in a fourth direction 736 substantiallyperpendicular to the first and second directions 711, 721. In oneembodiment, the third and fourth directions 731, 736 are substantiallyopposite. That is, the third direction 731 is radially outward and thefourth direction 736 is radially inward.

The redirection and slowing of the liquid carrier in the redirectionportion 737 of the top separation chamber 735, in conjunction with theflow of the liquid carrier through channels defined by the top formationof inclined plates 745, facilitates the separation of the lower-densityliquid 73 from the liquid carrier. The lower-density liquid 73accumulates in the collection portion 739 of the top separation chamber735. The liquid carrier 71B, now substantially free of both solidparticles 72 and lower-density liquid 73, flows in the first direction711 (e.g., downwards) in the third flow chamber 750 at the fourthvelocity that is less than the third velocity and that is less than therise-velocity of the lower-density liquid 73 in the liquid carrier. Therefined liquid carrier 71B flows out of the apparatus through an outlet754 of the third flow chamber 750. In one embodiment, the outlet 754 ofthe third flow chamber 750 is connected to an outlet pipe 756 whichextends from the outlet 754 to a point near the separator plate 755.Alternatively, the outlet 754 may be positioned near the bottom of thethird flow chamber just above the separator plate 755.

In one embodiment, the second flow chamber 720 includes coalescing mediato facilitate the separation of the lower-density liquid 73 from theliquid carrier. According to another embodiment, the second flow chamber720 is annulus formed around the third flow chamber 750. In oneembodiment, the third flow chamber 750 includes any type of backwashablemedia such as sand, black walnut shells or other backwashable media tocollect or trap any solids or lower-density liquid that are notseparated up to this stage from the liquid carrier. In one embodiment,the apparatus 700 includes a system for backwashing the media throughcomponent 703. In another embodiment flow chamber 750 could be in theshape of two cones with the small ends of each cone connected with thelarge end of the bottom cone connecting to flow chamber 720 and thelarge end of the top cone connecting being the start of flow chamber750. In this embodiment the two inclined plates 740 and 745 could beconnected into a single large inclined plate running from the bottom ofinclined plate 740 to the top of inclined plate 745.

Additional details relating to the apparatus 700 of FIG. 13 can be foundabove with reference to the similar and analogous embodiments describedabove. For example, the first and second flow chambers 710, 720, thebottom separation chamber 730, and the bottom inclined plates 740 areanalogous to the first and second flow chambers 110, 120, the separationchamber 130, and the inclined plates 140 of FIG. 1, respectively. Also,the second and third flow chambers 720, 750, the top separation chamber735, and the top inclined plates 745 are analogous to the first andsecond flow chambers 310, 320, the separation chamber 330, and theinclined plates 340 of FIG. 9, respectively.

As described above, the apparatus 700 may include other features thatfacilitate or otherwise improve the ease, effectiveness, and/or degreeof the separation. For example, in one embodiment the second flowchamber 720 includes coalescing media to improve the separation of thelower-density liquid from the liquid carrier. In another embodiment,back-washable media or other filters may be positioned in the third flowchamber to further refine the liquid carrier. In another embodiment theinclined plates are extended to connect inclined plates 740 to inclinedplates 745 to form one long continuous inclined plate 740/745.

FIG. 17 is a schematic flow chart diagram of a method 780 for removingboth solid particles and a lower-density liquid from a liquid stream,according to one embodiment. The solid particles have a specific gravitythat is greater than the specific gravity of the liquid carrier and thelower-density liquid has a specific gravity that is less than thespecific gravity of the liquid carrier. The method 780 includes flowingthe liquid stream through a first flow chamber in a first direction at afirst velocity at 781. The first direction is substantially parallel togravity and the first velocity is greater than a settling velocity ofthe solid particles in the liquid carrier. The method 780 furtherincludes redirecting the liquid carrier 180 degrees such that the liquidcarrier flows from the first flow chamber to a second flow chamber in asecond direction opposite the first direction at a second velocity lessthan the settling velocity at 782. The method 780 also includes, duringredirecting the liquid carrier, flowing the liquid carrier into inclinedchannels in a third direction substantially perpendicular to the firstand second directions at 783. The inclined channels are defined byinclined plates and fluidly couple an outlet of the first flow chamberand an inlet of the second flow chamber. The method 780 also includescollecting the solid particles as the solid particles fall out of theliquid carrier during redirecting the liquid carrier from the first flowchamber to the second flow chamber at 784 and flowing the liquid streamthrough the second flow chamber in the second direction at 785. In oneembodiment, the second flow velocity is increased in the second flowchamber to a third velocity, which may have the same magnitude as thefirst velocity. The third velocity is greater than a rise-velocity ofthe lower-density liquid in the liquid carrier. The method 780 alsoincludes redirecting the liquid carrier 180 degrees such that the liquidcarrier flows from the second flow chamber at the third velocity to athird flow chamber in the first direction at the fourth velocity at 786and collecting the lower-density liquid as the lower-density liquidrises out of the liquid carrier during redirecting the liquid carrierfrom the second flow chamber to the third flow chamber at 787.

In one embodiment, during redirecting the liquid carrier from the secondflow chamber to the third flow chamber, the liquid carrier flows out oftop inclined channels in a fourth direction substantially perpendicularto the first and second directions. The top inclined channels aredefined by top inclined plates and fluidly couple an outlet of thesecond flow chamber and an inlet of the third flow chamber.

FIG. 18 is a schematic block diagram of a system 790 for removing bothsolid particles and a lower-density liquid from a liquid stream 70,according to one embodiment. The system 290 shows how the variousapparatus 100 through 700 might be used in a treatment system. Thesystem also includes a chemical treatment subsystem 794 that receivesand disinfects the liquid carrier 71 from the second clarifier 792 and afilter 793 that receives and further clarifies the liquid carrier 71from the second clarifier subsystem 791. In one embodiment, the filter793 receives the refined liquid carrier 71 from the second clarifier 792before the chemical treatment subsystem 794. In another embodiment, thechemical treatment subsystem 794 receives the refined liquid carrier 71from the second clarifier 792 before the filter 793. Regardless theorder, the filtered liquid carrier 75 constitutes a refined liquidstream. In one embodiment, the system 790 further includes one or moreof the following: a pH adjustment subsystem, a de-emulsifier subsystem,a desalination subsystem, and a flocculant subsystem.

FIG. 19 is a partial cross-sectional view of an apparatus 800 forremoving heavier material and lighter material from a fluid stream,according to one embodiment. Similar to embodiments described above, theillustrated embodiment of FIG. 19 includes Embodiments described beloware similar to the embodiment shown in FIG. 13 and described above. Forexample, embodiments may remove one or both of heavier waste and lighterwaste. The apparatus 800 is capable of operating at atmosphericpressure. Because the apparatus 800 is capable of operating atatmospheric pressure, the apparatus 800 may be open to the atmosphere.In the alternative, the apparatus 800 may also be closed to theatmosphere.

The illustrated embodiment includes an inlet 802, a power unit 804, adiffuser 806, a cone structure 808, a transition portion 810, a platepack 812, a lower collection chamber 814, a solid waste dump 816, anupper collection reservoir 818, and an outlet 820. Some or all of thecomponents of the apparatus 800 are similar to those described abovewith reference to FIGS. 1-6, 9, 10, and 13-16. For example, the angle ofthe inclined plates 812 may be similar in angle and arrangement to theinclined plates 745 of FIG. 16.

The illustrated inlet 802 facilitates supply of a liquid stream 803through the inlet 802. The liquid stream 803 may be pumped or gravityfed. The power unit 804 drives an internal auger, vibrator, pump, orother mechanism 821 that helps force the solids down the cone and out awaste valve 816. The liquid stream 803 may also be delivered to theapparatus 800 by a pumping force applied remotely from the apparatus800. The liquid stream 803 enters the diffuser 806 from the inlet 802.The diffuser 806 directs a diffused liquid stream 807 into the conestructure 808. The diffuser 806 is shaped to disrupt or change thedirection of all or a portion of the liquid stream 803 to form thediffused liquid stream 807. Disruption of the liquid stream 803 mayfacilitate a decrease in flow velocity in a particular direction,fallout of heavier waste, and reduction in turbulence of the liquidstream. The diffuser 806 reduces disturbance, by the liquid stream 803,of collected heavier waste at a lower collection chamber 814 at or nearthe bottom of the apparatus 800 by reducing flow velocity and or flowenergy of the liquid stream 803 in the downward direction.

The diffused liquid stream 807 moves gravitationally downward throughthe cone structure 808. The cone structure 808 has a cross-sectionalarea that increases in the downward direction as a flow moves downwardthrough the cone structure 808, the velocity of the flow decreases as itfills the increasing area. As the liquid stream moves through theincreasing cross-section of the cone structure 808, the velocity of theliquid stream drops progressively. As the velocity drops, heavier waste811 such as solid particulate or liquid waste having a specific gravitygreater than that of the liquid carrier in the liquid stream falls outof the liquid stream. In some embodiments, the liquid stream proceedsdown the cone structure 808 in a first direction, that is a generallygravitationally downward direction, until it reaches the transitionportion 810. At the transition portion 810, the liquid stream encountersthe plate pack 812. At the transition portion 810, the liquid streamchanges direction from the first direction to a radially outwarddirection perpendicular to the first direction.

In the illustrated embodiment, the transition portion 810 is the regionin which the diffused liquid stream 807 moves from the cone structure808 and passes into the plate pack 812. As the diffused liquid stream807 proceeds through the transition portion 810 and across the platepack 812, the diffused liquid stream 807 is formed into a laminar liquidstream 809 and directed in a second direction parallel to and oppositethe first direction. The plate pack 812 creates a laminar flow conditionbetween the plates of the plate pack 812. The laminar flow conditionfurther facilitates fallout of heavier waste from the laminar liquidstream 809. The circular shape of the plate pack 812 facilitates anefficient fit within the apparatus 800. A portion of the heavier wastefalls out before the liquid stream 807 encounters the plates of theplate pack 812. This reduces the chance of waste clogging the plate pack812. The plate pack 812 has a plate spacing which results in a highersurface area efficiency with a reduced footprint of the apparatus 800.The laminar flow condition forms boundary conditions next to the surfaceof each of the plates of the plate pack 812. The boundary condition is azero-velocity flow which captures and separates waste from the laminarliquid stream 809. Additionally, the radially extending helical geometryof the plate pack 812 creates a raking effect which directs waste to anouter edge of the plate pack 812 which removes waste from the main flowpath and further facilitates separation of the waste from the laminarliquid stream and reduces the chance of re-entrainment of the waste onceseparated. Furthermore, the radial aspect of the plate pack 812 resultsin the plate spacing increasing as the plate pack 812 extends radiallyoutward from the cone structure 808. This increasing diameter of thevessel towards the outside of the plate pack 812 causes an additionaldrop in flow velocity further increasing separation efficient of theplate pack 812. In one example, the plate pack 812 includes two-hundredor more or less than two-hundred plates.

The heavier waste that has fallen out is captured in the lowercollection chamber 814. The lower collection chamber 814 may include oneor more of an auger, a vibrator, and the like to help facilitate themovement of the solids to the bottom of collection chamber 814. Thelower collection chamber 814 is coupled to a waste valve 816. The wastevalve 816 facilitates removal of the solid particulate waste from theapparatus 800. For example, the waste valve 816 includes an extractionmechanism to remove heavier particulate and fluid waste from the lowercollection chamber 814. The waste valve 816 may be a manually orautomatically operated valve. The heavier waste coming out the wastevalve 816 may be in a consistency ranging from a thick slurry to a thickpaste depending on operation conditions.

The plate pack 812 facilitates separation of lighter gravity fluids andsolids. For example, the plate pack 812 may separate oils, buoyant orsemi-buoyant particulates, foam and the like from the liquid stream. Theplate pack 812 may include one or more additional features, such as acurved leading edge, a hat, or the like to improve separation of lighterwaste fluids and particulates from the liquid stream. The plate pack 812may include hats coupled to the top of one or more of the plates in theplate pack 812 to collect lighter waste fluids and particulates anddirect them through a collection intake 817 into an upper collectionreservoir 818. The collection intake 817 may be formed at theintersection of one or more of the plates of the plate pack 812 and theupper collection reservoir 818. Embodiments which includes hats areshown and described below with reference to FIG. 23. The lighter waste813 is extracted from the upper collection reservoir 818 via removaloutlet 819 either by pumping or by gravity flow to a separate holdingtank or receptacle. This embodiment will handle small concentrations oflighter waste 813. In one embodiment, a collection reservoir and a weirsystem can be added at the top of the cone with a different outlet pipeto collect the refined liquid stream 815 along with a new wall forming anew flow chamber. If the new weir height is set lower than the weirheight leading to outlet 820 this embodiment will allow the lighterwaste 813 to flow through outlet 820 and the refined liquid stream 815will flow down the new wall, up the new flow chamber, over the new weirand out the new outlet, forming a trap so the lighter waste 813 can'tflow through the trap. This embodiment will handle high concentrationsof lighter waste 813.

The refined liquid stream 815 rises to the top of the vessel and gravityflows over the top of the upper collection reservoir 818 over a weir andout the refined liquid stream outlet 829. Post-filtering or separationstructures may be incorporated at or near the outlet 820 to furtherfilter, separate, or refine materials taken from the apparatus 800.

FIG. 20 is a perspective view of an assembly 830 of the plate pack 812of FIG. 19 mounted on a frame 832, according to one embodiment. In theillustrated embodiment, the frame 832 is disposed on the cone structure808 which is described above with respect to FIG. 19. The frame 832forms a platform with one or more mounting locations. The mountinglocations may facilitate mounting of pumps, motors, inlets, outlets,screens, or the like. The frame 832 also supports the plate pack 812 ina liquid refinement apparatus.

The frame 832 may be coupled to the cone 808 of the plate pack 812 bywelding or with a flanged connection. In some embodiments, the plates ofthe plate pack 812 are coupled to the upper collection reservoir 818 viaone or more of a tab-and-slot connection, a weld, or other joining orbonding methods.

In the illustrated embodiment, the plates of the plate pack 812 are alsocoupled to one or more bands 834. The band(s) 834 provides support tothe plates 812 to preserve proper alignment and provide structuralintegrity. Another function of the band(s) 834 is to facilitate assemblyand maintenance on the plate pack 812.

The illustrated embodiment of the plate pack 812 includes hats 836applied to the plates of the plate pack 812. One or more of the platesof the plate pack 812 include the hats 836 at an upper edge of theplates of the plate pack 812. The hats 836 may have a geometry to catchlighter contaminants, which tend to float to the top of the plate pack830, and direct them outward to the upper collection reservoir 818. Thehats 836 may also facilitate dissipation of foam collected near a topedge of the plates of the plate pack 812.

FIG. 21 is a bottom perspective view of the plate pack 812 of FIG. 19,according to one embodiment. In the illustrated embodiment, the diffuser806 protrudes downward through the cone structure 808. While thediffuser 806 is shown as mounted to the frame 832, it may also bemounted to the cone structure 808. In the illustrated embodiment, thecone structure 808 is a cone having a circular shaped cross-section. Thecone structure 808 may also have other geometries, such as an ellipticalcone, a pyramid such as a triangular or square pyramid, or the like.

The plates of the plate pack 812 are coupled to the cone structure 808.In the illustrated embodiment, the internal edges 835 of the plates ofthe plate pack 812 continue the geometry of the cone structure 808. Inother words, the internal edges 835 of the plates follow the outwardpath formed by the expanding geometry of the cone structure 808 suchthat the geometry of the cone structure 808 is matched and projectedalong the same path by the internal edges 835 of the plates. In anotherembodiment, the portion of the plate that extends below the cone canextend straight down from the cone or have other shapes or geometries.The internal edges 835 may be bent a few degrees to adjust the spacingbetween the plates. In one embodiment, the incoming flow enters the conein a cyclonic direction which is the same direction that the internaledges 835 are facing. The geometry of the internal edges 835 causes theliquid stream 807 to make a 180-degree change in direction to enter theplates 835. The interior of the cone structure 808 forms a first flowchamber. The first flow chamber facilitates flow of a liquid stream in afirst direction which is generally gravitationally downward directiondue to the arrangement of the cone structure 808. The diffuser 806 mayprovide at least a portion of the downward flow direction or diffuse theflow into the cone structure 808 at which point the cone structure 808directs the flow downward through the apparatus 800.

In the illustrated embodiment, the plates 812 include two alternatingplate geometries. Half of the plates include a hat 836 at the top edgeof the plate, which can be in various shapes as shown in FIG. 23. Inbetween each of the plates with hats 836, is one or more smallerplate(s). The geometry of each hat 836 occupies additional space in aplate pack 812. The smaller plates fit in between the plates with hats836 to increase the plate surface area of the plate pack 812 andincrease separation efficiencies. In the embodiment shown in apparatus800, every other plate has a hat 836 with smaller plates in between withno hats. In another embodiment, multiple smaller plates are arranged inbetween the plates with hats 836. While the illustrated embodiment ofthe plates of the plate pack 812 are shown as alternating, the plates ofthe plate pack 812 may also be uniform. The plates of the plate pack 812may include a plurality of geometries. The plates 812 may be arranged inone or more configurations such as patterned or random arrangements.

FIG. 22 is a perspective view of the plate pack 812 of FIG. 20 withoutthe mounting frame 832, according to one embodiment. In the illustratedembodiment, a removal outlet 838 is shown. The removal outlet 838 isillustrated as coupled to a top surface of the upper collectionreservoir 818 of the plate pack 812. The removal outlet 838 may also bepositioned on another part of the plate pack 812 or on another portionor surface of the upper collection reservoir 818.

In the illustrated embodiment, the plate pack 812 includes hats 836 onthe plates of the plate pack 812. The plates 812 and hats 836 may bepermanently or removably coupled to the cone structure 808 with one ormore of tabs that penetrate into the cone structure 808 and by tackwelding the plates 812 to the cone structure 808, thus forming a rigidand structurally solid assembly. As shown, the plates of the plate pack812 and hats 836 are angled upward from the cone structure 808 to thelighter waste collection reservoir 818. The plates of the plate pack 812and the hats 836 may be perpendicular to the incident surface of thecone structure 808. The plates of the plate pack 812 and the hats 836may also be arranged in a horizontal arrangement with no upward radialangle. In some embodiments, the slope or upward angle of the upper edgeof the plates of the plate pack 812 with the hats 836 disposed on theupper edge of one or more of the plates of the plate pack 812facilitates movement of the lighter waste materials radially outwardinto the upper collection reservoir 818. The slope of the upward angleof the plates of the plate pack 812 and the hats 836 may vary. In someembodiments, at least one of the plates of the plate pack 812 and thehats 836 includes a surface treatment to prevent adhesion, sticking, orbuildup of waste material. For example, the plates of the plate pack 812and/or hats 836 may be polished or coated.

FIG. 23 is a cross-sectional view of the plate pack 812 of FIG. 22,according to one embodiment. In the illustrated embodiment, the platepack 812 includes a plurality of plates having a radial arrangementhaving a helical form with a centralized focal. In the illustratedembodiment, the plate pack 812 extends radially outward from the conestructure 808. As described above, with respect to FIG. 1, theinclination of the plates of the plate pack 812 is between about 20degrees and about 70 degrees.

In the illustrated embodiment, the hats 836 include hooks or u-shapedstructures formed on the upper edge of the plates of the plate pack 812.The hats 836 lead from the cone structure 808 radially upwards thelighter waste collection reservoir 818. The lighter waste collectionreservoir 818 may form a single container wrapping around an upperportion of the plate pack 812 with a single removal outlet 838 or thelighter waste collection reservoir 818 may include a plurality ofseparate collection structures each with a corresponding removal outlet838.

The hats 836 may be a unified part of the plates of the plate pack 812or may be separate structures coupled to corresponding plates of theplate pack 812. The hats 836 may have a consistent geometry along theirlength or a geometry which varies along their length. The hats 836 mayhave the same or similar geometry and position relative to one anotheror one or more of the hats 836 may have a position and/or geometrydifferent from another of the hats 836.

FIG. 23 illustrates several embodiments of the hats 836 a-d. In thefirst illustrated embodiment, the hats 836 may include one or moresquare hats 836 a. The square hat 836 a is formed on or coupled to anupper edge 839 of one or more of the plates of the plate pack 812. Thesquare hat 836 a affects the flow path of the liquid stream 809 toseparate the lighter waste 813 from the refined liquid stream 815. Thesquare hat 836 a catches and directs the lighter waste 813 out to theupper collection reservoir 818.

Other embodiments of the hats 836 are also shown. For example, the hats836 may include one or more of a rounded hat 836 b. The rounded hat 836b may be formed in or coupled to one or more plates of the plate pack812. The rounded shaped of the rounded hat 836 b may simplifymanufacturing and provide different fluid dynamic properties in theliquid streams (both waste and refined) which encounter the rounded hat836 b. The hat 836 may have other shapes and geometries such as apartial arc hat 836 c and an angled hat 836 d. Different geometries andembodiments of the hats 836 provide different fluid dynamic advantagesand effects as well as different advantages in a manufacturing and/orassembly process.

FIG. 24 is a side view of a cone structure 808, according to oneembodiment. In the illustrated embodiment, the cone structure 808includes a side wall having an angle 840 relative to the horizontalplane. The angle 840 of the side wall of the cone structure 808 isapproximately 60°. The term “approximately 60°” includes any angle thatis within manufacturing tolerances of 60° or approaches 60°.Alternatively, the angle of the side wall of the cone structure 808 isbetween approximately 60° and 45°. Other angles and ranges of angles arealso contemplated.

The space within the cone structure 808 forms a first flow chamber 841.The first flow chamber 841 directs a liquid stream 809 along a firstdirection which is gravitationally downward. As the horizontalcross-section area of the cone structure 808 expands along the height ofthe cone structure 808, a velocity of the liquid stream 809 decreases.The liquid stream 809 then flows into a second flow chamber 843 whichforms a conical annulus surrounding the cone structure 808. As thecross-sectional area of the second flow chamber 843 increases in thesecond or upward direction, the velocity of the liquid stream 809 isfurther reduced. The plate pack 812 of FIG. 19 at least partiallycoincides with the second flow chamber 843 but is omitted here forclarity.

In the illustrated embodiment, the internal edges 835 of the plates ofthe plate pack 812 are shown. As described above with reference to FIG.21, the internal edges 835 of the plates form an extension,continuation, or projection of the cone structure 808. In other words,the internal edges 835 of the plates maintain the same angle 840 as thatof the cone structure 808. Alternatively, the internal edges 835 mayhave an angle that is different from that of the cone structure 808.

The illustrated embodiment of FIG. 24 also includes notches 842 formedin the upper portion of the cone structure 808. The notches 842 areformed to correspond with components such as the frame 832 shown anddescribed above with respect to FIG. 20. Alternatively, the top of thecone can be uniformly welded to a flange and the flange can bolt to theframe 832 shown and described above with respect to FIG. 20.

In the illustrated embodiment, the cone structure 808 also includesslots 844. The slots 844 are attachment points to facilitate uniform andconsistent attachment of the plates 812 to the cone structure 808.Attachment can either be by slipping tabs into the slots that are bentover or welded on the back side of the cone structure 808. As the slots844 coincide with the plates of the plate pack 812, the slots 844 areformed in a helical pattern on the cone structure 808. Because, theplates of the plate pack 812 may have other geometries or becauseadditional slots 844 may be included which are not associated with theplates, the slots 844 may also be arranged in different configurationsthan shown in FIG. 24.

As shown in FIG. 24, the cone structure 808 is substantially linear. Inother words, the illustrated embodiment includes straight side walls.However, the cone structure 808 may also be substantially non-linear.For example, the cone structure 808 may include curved side walls thatcurve outward in a bell-like shape or inward in a spherical manner.Similarly, the cone structure 808 may include one or more variations inthe geometry of the side walls with different geometries at differentportions of the cone structure 808.

FIG. 25 is a schematic flow chart diagram of a method 850 for removingboth solid particles and a lower-density liquid from a liquid stream,according to one embodiment.

The illustrated embodiment of the method 850 includes, at block 852,directing a liquid carrier in a first direction gravitationally downwardat a first velocity through a first conical flow chamber from a narrowupper portion to a broad lower portion of the conical flow chamber. Theliquid carrier includes one or more of a solid particulate and a lowerdensity fluid.

At block 854, the method 850 includes directing the liquid carrier fromthe first conical flow chamber in a second conical flow chamber in asecond direction opposite the first direction. The second conical flowchamber includes inclined plates.

At block 856, the method 850 includes collecting a portion of the solidparticulate having a specific gravity that is greater than a specificgravity of the liquid carrier at a lower collection chamber.

At block 858, the method 850 includes collecting the lower density fluidand a portion of the solid particulate suspended in the liquid carrieran upper collection reservoir. One or more of the inclined platesincludes a u-shaped hat disposed on an upper edge of the one or moreincluded plates to direct the separated lower density fluid and theportion of the solid particulate having a specific gravity that is lowerthan the specific gravity of the liquid carrier to the upper collectionreservoir.

In the above description, certain terms may be used such as “up,”“down,” “upper,” “lower,” “horizontal,” “vertical,” “left,” “right,” andthe like. These terms are used, where applicable, to provide someclarity of description when dealing with relative relationships. But,these terms are not intended to imply absolute relationships, positions,and/or orientations. For example, with respect to an object, an “upper”surface can become a “lower” surface simply by turning the object over.Nevertheless, it is still the same object. Further, the terms“including,” “comprising,” “having,” and variations thereof mean“including but not limited to” unless expressly specified otherwise.

Additionally, instances in this specification where one element is“coupled” to another element can include direct and indirect coupling.Direct coupling can be defined as one element coupled to and in somecontact with another element. Indirect coupling can be defined ascoupling between two elements not in direct contact with each other, buthaving one or more additional elements between the coupled elements.Further, as used herein, securing one element to another element caninclude direct securing and indirect securing. Additionally, as usedherein, “adjacent” does not necessarily denote contact. For example, oneelement can be adjacent another element without being in contact withthat element.

As used herein, the phrase “at least one of”, when used with a list ofitems, means different combinations of one or more of the listed itemsmay be used and only one of the items in the list may be needed. Theitem may be a particular object, thing, or category. In other words, “atleast one of” means any combination of items or number of items may beused from the list, but not all of the items in the list may berequired. For example, “at least one of item A, item B, and item C” maymean item A; item A and item B; item B; item A, item B, and item C; oritem B and item C; or some other suitable combination. In some cases,“at least one of item A, item B, and item C” may mean, for example,without limitation, two of item A, one of item B, and ten of item C;four of item B and seven of item C; or some other suitable combination.

Unless otherwise indicated, the terms “first,” “second,” etc. are usedherein merely as labels, and are not intended to impose ordinal,positional, or hierarchical requirements on the items to which theseterms refer. Moreover, reference to, e.g., a “second” item does notrequire or preclude the existence of, e.g., a “first” or lower-numbereditem, and/or, e.g., a “third” or higher-numbered item.

The schematic flow chart diagrams included herein are generally setforth as logical flow chart diagrams. As such, the depicted order andlabeled steps are indicative of one embodiment of the presented method.Other steps and methods may be conceived that are equivalent infunction, logic, or effect to one or more steps, or portions thereof, ofthe illustrated method. Additionally, the format and symbols employedare provided to explain the logical steps of the method and areunderstood not to limit the scope of the method. Although various arrowtypes and line types may be employed in the flow chart diagrams, theyare understood not to limit the scope of the corresponding method.Indeed, some arrows or other connectors may be used to indicate only thelogical flow of the method. For instance, an arrow may indicate awaiting or monitoring period of unspecified duration between enumeratedsteps of the depicted method. Additionally, the order in which aparticular method occurs may or may not strictly adhere to the order ofthe corresponding steps shown.

The subject matter of the present disclosure may be embodied in otherspecific forms without departing from its spirit or essentialcharacteristics. The described embodiments are to be considered in allrespects only as illustrative and not restrictive. The scope of thedisclosure is, therefore, indicated by the appended claims rather thanby the foregoing description. All changes which come within the meaningand range of equivalency of the claims are to be embraced within theirscope.

What is claimed is:
 1. An apparatus for refining a liquid stream,wherein the liquid stream comprises a liquid carrier having at least oneof a solid particulate and a lower density fluid mixed therein, theapparatus comprising: a first flow chamber for directing the liquidstream downwards in a first direction within the first flow chamber at afirst velocity, wherein first flow chamber is a cone structure and thefirst direction is substantially parallel to gravity and the firstvelocity is greater than a settling velocity of the solid particulate inthe liquid carrier, and wherein the cone structure has a cross-sectionalarea that increases in the first direction; a second flow chamber fordirecting the liquid carrier upwards in a second direction opposite thefirst direction at a second velocity less than the settling velocity;and plates disposed at least partially within the second flow chamberand at a transition between the first flow chamber and the second flowchamber, the plates having an inclined geometry to form an at leastpartially laminar flow condition in the liquid stream to separate aportion of the solid particulate having a specific gravity that isgreater than a specific gravity of the liquid carrier to a lowercollection chamber and the lower density fluid and a portion of thesolid particulate having a specific gravity that is less than thespecific gravity of the liquid carrier to an upper collection reservoir.2. The apparatus of claim 1, wherein one or more of the plates comprisesa hat disposed on an upper edge of the one or more plates to directseparated lower density fluid and a portion of the solid particulatewith a particle size small enough that the particle stays suspended inthe liquid stream to the upper collection reservoir.
 3. The apparatus ofclaim 2, wherein the hat comprises at least one of a square hat, acurved hat, and an angled hat disposed on the upper edge of the one ormore inclined plates.
 4. The apparatus of claim 1, wherein: the platesdefine inclined channels fluidly coupling an outlet of the first flowchamber and an inlet of the second flow chamber; and the liquid carrierflows into the inclined channels in a third direction perpendicular tothe first and second directions.
 5. The apparatus of claim 4, wherein:the second flow chamber is a conical annulus formed around the firstflow chamber; and the third direction is radially outward.
 6. Theapparatus of claim 5, wherein: the plates in the transition arecircumferentially spaced apart in an annular formation; and the annularformation of the plates is positioned proximate an inlet of, andsubstantially concentric with, the second flow chamber.
 7. The apparatusof claim 1, wherein the liquid stream does not require the use offlocculants to achieve refinement.
 8. The apparatus of claim 1, whereinthe slope of the cone structure is about 60 degrees.
 9. The apparatus ofclaim 1, wherein a slope of the inclined plates is between about 20degrees and about 70 degrees.
 10. The apparatus of claim 1, wherein theplates have a geometry to apply a raking effect to push waste radiallyoutward on the plates.
 11. The apparatus of claim 1, wherein theinclined plates are electrostatically charged.
 12. The apparatus ofclaim 1, further comprising at least one of a central auger and avibrator.
 13. The apparatus of claim 1, wherein a cross-sectional areaof the second flow chamber is larger than a cross-sectional area of thefirst flow chamber.
 14. The apparatus of claim 1, wherein the firstvelocity is about twice the second velocity.
 15. The apparatus of claim1, wherein the first flow chamber and the second flow chamber are freeof moving parts.
 16. The apparatus of claim 1, wherein the first flowchamber and the second flow chamber are free of interchangeable media.17. A method comprising: directing a liquid carrier in a first directiongravitationally downward at a first velocity through a first flowchamber from a narrow upper portion of a cone structure to a broad lowerportion of the first flow chamber, the liquid carrier comprising one ormore of a solid particulate and a lower density fluid; directing theliquid carrier from the first flow chamber into a second flow chamber ina second direction opposite the first direction, the second flow chambercomprising plates; collecting a portion of the solid particulate havinga specific gravity that is greater than a specific gravity of the liquidcarrier at a lower collection chamber; and collecting the lower densityfluid and a portion of the solid particulate suspended in the liquidstream, wherein one or more of the plates comprises a hat disposed on anupper edge of the one or more plates to direct the separated lowerdensity fluid and the portion of the solid particulate having a specificgravity that is lower than the specific gravity of the liquid carrier tothe upper collection reservoir.
 18. The method of claim 17, furthercomprising establishing a laminar flow condition in the liquid carrieras the liquid carrier moves across the plates, wherein the plates defineinclined channels fluidly coupling an outlet of the first flow chamberand an inlet of the second flow chamber.
 19. The method of claim 17,further comprising directing the liquid carrier from the first flowchamber to the second flow chamber by moving the liquid carrier in athird direction, the third direction being radially outward into thesecond flow chamber.
 20. A liquid stream refining system comprising: afirst flow chamber for directing the liquid stream downwards in a firstdirection within the first flow chamber at a first velocity, wherein thefirst flow chamber is conical in geometry and the first direction issubstantially downward and parallel to gravity and the first velocity isgreater than a settling velocity of a heavier waste in a liquid carrierof the liquid stream, and wherein the first flow chamber has across-sectional area that increases in the first direction; a secondflow chamber for directing the liquid carrier upwards in a seconddirection opposite the first direction at a second velocity less thanthe settling velocity; and a plate pack comprising a plurality of platesdisposed in an inclined helical arrangement at least partially withinthe second flow chamber and at a transition between the first flowchamber and the second flow chamber, the plurality of plates having ageometry to form an at least partially laminar flow condition in theliquid stream to separate a portion of the heavier waste having aspecific gravity that is greater than a specific gravity of the liquidcarrier to a lower collection chamber for extraction and a lighter wastehaving a specific gravity that is less than the specific gravity of theliquid carrier to an upper collection reservoir for extraction.